Choose PLC for Vacuum Forming project

[Mr_E 0]

Hi.

 

I am working on a project to build a GUI to be able to control the heat on an old vacuum forming machine from the late 90's whose own GUI stopped working.  I´m programming the GUI using Python. I know some basic electronics and programming. But I see this as a project to learn.

At thins point there will only be a few signals from the machine. For example emergency stop, heating mode: front / rear. Heating on / off. In the long run, I also want to be able to control the machine's movements, which will mean a number of additional signals in / out.

Outgoing, there will be significantly more signals. The machine has 110 300w infrared heaters which you should be able to control how much power (0-300w) each heater should have individually.

 

What I initially wonder is what PLC you would recommend for this project?

What should you use to be able to adjust the effect to each element?

[panic mode 246]

it depends on what you really want to accomplish. to narrow down the specs you need to specify number and type of I/O, any communication interfaces, budget etc. for example one thing to consider is cost of software and any drivers needed for communication.

Emergency stop is a safety device. PLC can monitor that state (for example for troubleshooting or indication) but not control EStop function unless PLC itself and relevant IO are also safety rated. 

How many heaters? If it is one or two, simple regulation using dimmer is ok (this is called random trigger). but this creates EMI and requires filtering but it is a way to go for dimming lights on a budget. another option is to use zero crossing triggering. this way load is turned on and off as sine is at zero point so there are no spikes, transients or harmonics. this is not suitable for visible lights due flicker but it is an excellent choice for heaters and loads that do not radiate visible light.

 

[Mr_E 0]

Hi,

Thanks for your reply. Sorry my reply was delayed. I had a son and life got in the way.

The budget is 10000 Euro / 11000 Dollars max. But I would be happy if I managed halfway.

There are 110 heaters. So there are quite a few and they should be managed individually. They look something like this on the machine http://www.plasticsmag.com/article_images/quartz_jf05cap.JPG
https://www.machinetic.com/tools/quartz-infrared-heating-elements

I am thinking that maybe I should start with what is best to regulate the heaters with. Can you use something like this: https://www.renhotecic.com/SCR-High-Power-Electronic-Voltage-Regulator-For-Dimming-Speed-Regulation-Temperature-Regulation-2000W-25A-0044188
If so, I am thinking that the PLC should simulates the potentiometer. Could it be something?

[BobLfoot 301]

IT might fall outside your price range but the RTP 3000 would support flow chart programming and high speed control of 110 pid loops quite easily.

http://rtpcorp.com/product-benefits/